.boiler survey  .boiler inspection

Boiler survey is Conducted every 2.5 years, twice in 5 years

Planning

1. Planning to be done and discuss with technical super.
2. Risk assessment to be done
3. Permit to work obtain
4. Check for necessary tools and spares
5. Check manual for special instruction and check past records
6. Next port steam consumption obtain
7. Personal involve to be briefed

Shutting down for survey

• Inform duty officer
• Change over M/E, A/E and boiler to DO
• Top up do service tank, stop all purifier.
• Stop tank heating and steam tracing
• Changeover boiler from auto to manual.
• Stop the boiler and purge for 3-5min
• Switch off power on panel and switch off circuit breaker for HFO pump and feed water pump
• Posted ‘do not start’ sign
• Shut main steam stop valve and shut fuel valve and feed water valve
• Let the boiler cool down
• When boiler pressure ~ 4 bar, carry out blow down
• When boiler pressure ~ 2 bar. Open vent
• Let the boiler cool down
• When sufficiently cooled at atmospheric pressure, open top manhole door with all safety precaution.
• Knock gently as may contain hot water/ steam
• When nothing coming out, open manhole with support of rope
• Open bottom hand hole door
• Ventilate for few hours.

Prepare for entry

1. Enclose space entry permit to be obtained
2. Wear proper PPE like safety shoes, helmet , hand gloves
3. Keep an inventory of tools taken inside
4. Keep one responsible engineer standby outside with clear emergency orders
5. Keep emergency breathing apparatus standby
6. Ensure proper lighting of ventilation
7. Carry a gas detector, manually calibrate it in open atmospheric condition
8. Ensure proper communication

Boiler inspection

I.  Foundation:

• Boiler supports, bolting and securing arrangements, (fixed and sliding seating, chocks, rolling stays if any) to be examined. (sbs)
• Look for sign of rust and wastage in the bolt and nuts.

II. Furnace: 

1. Check for distortion  
2. Distortion mainly due to:
   1. Overheating (excessive scaling, excessive thermal stresses etc.)
   1. Flame impingement (across the path of the flame)  
3. Check condition of refractory  
4. Check furnace bottom, should be free of oil deposits

III. Shell, tube plates and tubes:  

1. Weld cracks, in the way of valve openings  
2. Wastage in the way of manhole & hand hole flanges
3. Check Normal water region for cavitation, pitting etc.  
4. Inlet tube ends, for erosion/corrosion  
5. Checks for tube deformation, erosion, crack, wastage, s etc. 

IV. safety v/v: 

• safety v/v’s are to be overhauled and examined at each survey and opened as considered necessary by the surveyor  
• The proper operation of the safety v/v’s are to be confirmed at each survey  
• Boiler safety v/v’s easing gear is to be examined & tested satisfactory

 V.  All others boiler mountings: 

All boiler mountings to be overhauled for survey.

• Main steam stop valve  
• Air vent valve  
• Sampling v/v  
• Scum blow down v/v  
• Feed stop & check v/v  
• Water level gauge glass 
• Pressure gauge to be calibrated 
• Manhole covers  
• Soot blowers
• Blow down v/v  

VI. Hydraulic test:

1. To be carried out if an alteration/repairs have been carried out on highly stressed parts.
2. Major tube renewal has been done 
3. Shell plating renewal 
4. Usually, 1 .5 times the max Working Pressure 
5. Can be requested at the discretion [1] of the surveyor

VII. External inspection: 

Upon completion of the internal survey, the boiler is to be examined under steam, with the fuel oil burners and safety devices and all other mountings under working condition.

following alarm test to be done.

1. Water level high high – Automatic shutdown with alarm (requirement if ship fitted with steam operated machinery)
2. Water level high- Alarm
3. Water level low-ALARM 
4. Water level low-low – Automatic shutdown with alarm
5.  FD fan or flame failure- Automatic shutdown with alarm

VIII. Logbook

Review of boiler operation & feed water test records.

IX. Manual emergency shutdown:

• Boiler’s forced-draft fan & fuel oil service pumps are to be fitted with remote means of control situated outside the space in which they are located so that they can be stopped in the event of fire.
• Testing of local emergency stop function

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[1] the quality of behaving or speaking in such a way as to avoid causing offense or revealing private information.”she knew she could rely on his discretion”

• Boiler’s forced-draft fan & fuel oil service pumps are to be fitted with remote means of control situated outside the space in which they are located so that they can be stopped in the event of fire.
• Testing of local emergency stop function

Boiler Flash up procedure

.boiler flush up  .boiler cold start

1. internal surface to be clean and no tools and rags left inside
2. All openings of mountings cleaned properly
3. Mountings to be fixed back with new gaskets
4. Manhole, hand hole , furnace are closed
5. Ensure vent, alarms and pressure gauge connection valves are open
6. Ensure all drain valves are shut
7. Switch on power on boiler panel and put all circuit breaker to normal
8. Open fuel valve and feed water valve and start pump
9. Ensure all system running ok
10. Start filling boiler with water just below normal level as level will swell up when boiler fired
11. Fire the boiler at lowest possible rate
12. Continue fire intermittently. 1min fire- 10 min stop. After 1^st hour, 2min fire10 minute stop
13. When steam comes out vent, shut vent
14. Carry out gauge glass blow down
15. Check boiler for abnormalities
16. Adjust safety valve pressure setting
17. Slowly crack open main steam stop valve and open full
18. With boiler running, check all safety alarm.